Blends for foams, foams manufactured therefrom and articles comprising the same

ABSTRACT

Disclosed herein is a foamable composition comprising an olefin copolymer that comprises ethylene and an α-olefin; an unneutralized carboxylated olefin copolymer; a crosslinking agent; a blowing agent; and an activator; where a weight ratio of the activator to the unneutralized carboxylated olefin copolymer is greater than 0.3. Disclosed herein too is a method of manufacturing a foamable composition comprising blending together an olefin copolymer that comprises ethylene and an α-olefin; an unneutralized carboxylated olefin copolymer; a crosslinking agent; a blowing agent; and an activator to form the foamable composition; where a weight ratio of the activator to the unneutralized carboxylated olefin copolymer is greater than 0.3; heating the foamable composition to activate the blowing agent to form a foam; and crosslinking the foam.

BACKGROUND

This disclosure relates to blend for foams, foams manufactured therefrom and to articles comprising the same.

Polymeric foams are often used in a wide variety of different applications as thermal insulation, sound insulation, cushioning, filters, vibration and impact damping, and the like. Applications using such polymeric foams include electronic devices, food packing materials, clothing materials, building materials, interior and exterior parts of automobiles and home electric appliances, footwear, and the like.

Of the many commercially available foams, polyolefin foams and polyethylene vinyl/acetate foams are often used in footwear where properties such as cushioning and flexibility are desirable. Polyolefin foams have a lower compression set at elevated temperatures when compared with poly(ethylene/vinyl acetate) (EVA) foams. This difference is often attributed to the melting point of the polyolefin foams and to the degree of curing amongst other factors.

It is therefore desirable to manufacture polyolefin foams that display better compression set resistance when compared with poly(ethylene/vinyl acetate) foams so that products that use these foams will have superior properties when compared with products that use poly(ethylene/vinyl acetate) foams.

SUMMARY

Disclosed herein is a foamable composition comprising an olefin copolymer that comprises ethylene and an α-olefin; an unneutralized carboxylated olefin copolymer, a crosslinking agent; a blowing agent; and an activator; where a weight ratio of the activator to the unneutralized carboxylated olefin copolymer is greater than 0.3.

Disclosed herein too is a method of manufacturing a foamable composition comprising blending together an olefin copolymer that comprises ethylene and an α-olefin; an unneutralized carboxylated olefin copolymer: a crosslinking agent; a blowing agent; and an activator to form a foam; where a weight ratio of the activator to the unneutralized carboxylated olefin copolymer is greater than 0.3; heating the foamable composition to activate the blowing agent and crosslinking agent to form a crosslinked foam.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows the melting point/density relationship for olefin block copolymers; and

FIG. 2 is a graph that depicts the MDR (moving die rheometer) curing torque of OBC system with (IE-1 and IE-4) or without (CE-3) E-MAA copolymer at the same crosslinking agent level;

FIG. 3 is a graph that depicts MDR curing torque of EVA system with or without (CE-5˜CE-7) E-MA A copolymer at the same crosslinking agent level;

FIG. 4 is a graph of foam hardness at different foam density for an OBC foam with or without E-MAA;

FIG. 5 is a graph of foam compressive strength at different foam density for an OBC foam with or without E-MAA;

FIG. 6 is a graph of foam compression set against split tear at different foam density for OBC foam with or without E-MAA;

FIG. 7 is a graph of foam compression set at different foam density for OBC and EVA foam with or without E-MAA; and

FIG. 8 depicts a Spider chart that compares the performance of CE-2 (0 wt % E-MAA in OBC) with IE-6 (10 wt % E-MAA in OBC) foam.

DETAILED DESCRIPTION

“Composition” and like terms mean a mixture of two or more materials, such as a polymer which is blended with other polymers or which contains additives, fillers, or the like. Included in compositions are pre-reaction, reaction and post-reaction mixtures the latter of which will include reaction products and by-products as well as unreacted components of the reaction mixture and decomposition products, if any, formed from the one or more components of the pre-reaction or reaction mixture.

“Blend”, “polymer blend” and like terms mean a composition of two or more polymers. Such a blend may or may not be miscible. Such a blend may or may not be phase separated. Such a blend may or may not contain one or more domain configurations, as determined from transmission electron spectroscopy, light scattering, x-ray scattering, and any other method known in the art. Blends are not laminates, but one or more layers of a laminate may contain a blend.

“Polymer” means a compound prepared by polymerizing monomers, whether of the same or a different type. The generic term polymer thus embraces the term homopolymer, usually employed to refer to polymers prepared from only one type of monomer, and the term interpolymer as defined below. It also embraces all forms of interpolymers, e.g., random, block, and the like. The terms “ethylene/a-olefin polymer” is indicative of interpolymers as described below. It is noted that although a polymer is often referred to as being “made of” monomers, “based on” a specified monomer or monomer type, “containing” a specified monomer content, or the like, this is obviously understood to be referring to the polymerized remnant of the specified monomer and not to the unpolymerized species.

“Interpolymer” means a polymer prepared by the polymerization of at least two different monomers. This generic term includes copolymers, usually employed to refer to polymers prepared from two or more different monomers, and includes polymers prepared from more than two different monomers, e.g., terpolymers, tetrapolymers, and the like.

“Polyolefin”, “polyolefin polymer”, “polyolefin resin” and like terms mean a polymer produced from a simple olefin (also called an alkene with the general formula C_(n)H_(2n)) as a monomer. Polyethylene is produced by polymerizing ethylene with or without one or more comonomers. Thus, polyolefins include interpolymers such as ethylene-α-olefin copolymers, and the like.

“Melting Point” as used here (also referred to a melting peak in reference to the shape of the plotted DSC curve) is typically measured by the DSC (Differential Scanning Calorimetry) technique for measuring the melting points or peaks of polyolefins as described in U.S. Pat. No. 5,783,638. The rate of heating during the measuring of the melting point can vary from 10° C./minute to 20° C./minute. The atmosphere during the conduction of the heating can be an inert gas such as nitrogen or argon. It should be noted that many blends comprising two or more polyolefins will have more than one melting point or peak; many individual polyolefins will comprise only one melting point or peak.

The term ‘and/or” includes both “and” as well as “or”. For example, the term A and/or B is construed to mean A, B or A and B.

“Low crystallinity”, “high crystallinity” and like terms are used in a relative sense, not in an absolute sense. However, low crystallinity components have crystallinity of from 1 to 25, preferably from 1 to 20, and more preferably from 1 to 15 weight percent crystallinity, based on the total weight of the foam. High crystallinity components have crystallinity of 25 weight percent or greater, based on the total weight of the foam.

High crystalline polymers often include linear low density polyethylene (LLDPE), low density polyethylene (LDPE), LLDPE/LDPE blends, high density polyethylene (HDPE), substantially linear ethylene polymer (SLEP), random copolymer (RCP), and the like, and various blends thereof. Low crystallinity polymers of particular interest preferably include ethylene/α-olefin multi-block interpolymers defined and discussed in copending PCT Application No. PCT/US2005/008917, filed on Mar. 17, 2005 and published on Sep. 29, 2005 as WO/2005/090427, which in turn claims priority to U.S. Provisional Application No. 60/553,906, filed Mar. 17, 2004, both which are incorporated by reference. Low crystalline polymers also include propylene/ethylene.

The term “polymer” generally includes, but is not limited to, homopolymers, copolymers, such as, for example, block, graft, random and alternating copolymers, terpolymers, and the like, and blends and modifications of the same. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic and random symmetries.

All percentages specified herein are weight percentages unless otherwise specified.

“Interpolymer” means a polymer prepared by the polymerization of at least two different types of monomers. The generic term “interpolymer” includes the term “copolymer” (which is usually employed to refer to a polymer prepared from two different monomers) as well as the term “terpolymer” (which is usually employed to refer to a polymer prepared from three different types of monomers). It also encompasses polymers made by polymerizing four or more types of monomers.

Disclosed herein is a foamable composition that can be used for manufacturing foams that have cell sizes and crosslink densities that ensure a lower compression set when compared with other commercially available foams that are used in footwear applications. The foams have a density less than or equal to 0.23 g/cc, preferably less than or equal to 0.22 g/cc, and more preferably less than or equal to 0.20 g/cc. The compression set resistance and compressive strength reflects the supporting ability of the foam. A good compression set resistance and compressive strength increases the shoe durability.

The foamable composition comprises a polyolefin elastomer, a carboxylated olefin copolymer, a blowing agent, a catalyst package and a crosslinking agent. The foamable composition contains no ionomer (neutralized carboxylated olefin copolymer) prior to being foamed. In an embodiment, the resulting foam may contain ionomer (neutralized carboxylated olefin copolymer) that is formed during the process of foaming or crosslinking.

In an embodiment, no ionomer is added to the foamable composition prior to crosslinking and foaming and the ionomer may be formed in-situ as a result of a reaction between the ingredients (e.g., polyolefin elastomer, a carboxylated olefin copolymer, a blowing agent, a catalyst package and a crosslinking agent) of the foamable composition during the crosslinking or foaming.

In an exemplary embodiment, the polyolefin elastomer can comprise an olefin block copolymer (OBC) and/or an olefin random copolymer. The polyolefin elastomer can be a copolymer that comprises ethylene and an α-olefin. The polyolefin elastomer can be homogeneously or heterogeneously branched.

Copolymers comprising ethylene and an α-olefin are also known as ethylene/α-olefin interpolymers. The term “ethylene/α-olefin interpolymer” generally refers to polymers comprising ethylene and an α-olefin having 3 or more carbon atoms. Preferably, ethylene comprises the majority mole fraction of the whole polymer, i.e., ethylene comprises at least 50 mole percent of the whole polymer. More preferably ethylene comprises at least 60 mole percent, at least 70 mole percent, or at least 80 mole percent, with the substantial remainder of the whole polymer comprising at least one other comonomer that is preferably an α-olefin having 3 or more carbon atoms. For many ethylene/octene copolymers, the preferred composition comprises an ethylene content greater than 80 mole percent of the whole polymer and an octene content of from 10 to 20, preferably from 15 to 20 mole percent of the whole polymer. In some embodiments, the ethylene/α-olefin interpolymers do not include those produced in low yields or in a minor amount or as a by-product of a chemical process. While the ethylene/α-olefin interpolymers can be blended with one or more polymers, the as-produced ethylene/α-olefin interpolymers are substantially pure and often comprise a major component of the reaction product of a polymerization process.

The ethylene/α-olefin interpolymers comprise ethylene and one or more copolymerizable α-olefin comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties. That is, the ethylene/α-olefin interpolymers are block interpolymers, preferably multi-block interpolymers or copolymers. The terms “interpolymer” and copolymer” are used interchangeably herein. In some embodiments, the multi-block copolymer can be represented by the following formula:

(AB)_(n)

where n is at least 1, preferably an integer greater than 1, such as 2, 3, 4, 5,10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, or higher, “A” represents a hard block or segment and “B” represents a soft block or segment. Preferably, A's and B's are linked in a substantially linear fashion, as opposed to a substantially branched or substantially star-shaped fashion. In other embodiments, A blocks and B blocks are randomly distributed along the polymer chain.

In still other embodiments, the block copolymers do not usually have a third type of block, which comprises different comonomer(s). In yet other embodiments, each of block A and block B has monomers or comonomers substantially randomly distributed within the block. In other words, neither block A nor block B comprises two or more sub-segments (or sub-blocks) of distinct composition, such as a tip segment, which has a substantially different composition than the rest of the block.

The multi-block polymers typically comprise various amounts of “hard” and “soft” segments. “Hard” segments refer to blocks of polymerized units in which ethylene is present in an amount greater than 95 weight percent, and preferably greater than 98 weight percent based on the weight of the polymer. In other words, the comonomer content (content of monomers other than ethylene) in the hard segments is less than 5 weight percent, and preferably less than 2 weight percent based on the weight of the polymer. In some embodiments, the hard segments comprise all or substantially all ethylene. “Soft” segments, on the other hand, refer to blocks of polymerized units in which the comonomer content (content of monomers other than ethylene) is greater than 5 weight percent, preferably greater than 8 weight percent, greater than 10 weight percent, or greater than 15 weight percent based on the weight of the polymer. In some embodiments, the comonomer content in the soft segments can be greater than 20 weight percent, greater than 25 weight percent, greater than 30 weight percent, greater than 35 weight percent, greater than 40 weight percent, greater than 45 weight percent, greater than 50 weight percent, or greater than 60 weight percent.

The soft segments can often be present in a block interpolymer from 1 weight percent to 99 weight percent of the total weight of the block interpolymer, preferably from 5 weight percent to 95 weight percent, from 10 weight percent to 90 weight percent, from 15 weight percent to 85 weight percent, from 20 weight percent to 80 weight percent, from 25 weight percent to 75 weight percent, from 30 weight percent to 70 weight percent, from 35 weight percent to 65 weight percent, from 40 weight percent to 60 weight percent, or from 45 weight percent to 55 weight percent of the total weight of the block interpolymer. Conversely, the hard segments can be present in similar ranges. The soft segment weight percentage and the hard segment weight percentage can be calculated based on data obtained from DSC or NMR. Such methods and calculations are disclosed in a concurrently filed U.S. patent application Ser. No. 11/376,835, entitled “Ethylene/α-Olefin Block Interpolymers”, filed on Mar. 15, 2006, in the name of Colin L. P. Shan, Lonnie Hazlitt, et. al. and assigned to Dow Global Technologies Inc., the disclosure of which is incorporated by reference herein in its entirety.

In an embodiment, the ethylene/α-olefin interpolymers used in embodiments (also referred to as “interpolymer” or “polymer”) comprise ethylene and one or more copolymerizable α-olefin comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (block interpolymer), preferably a multi-block copolymer. The ethylene/α-olefin interpolymers are characterized by one or more of the aspects described as follows.

In one aspect, the ethylene/α-olefin interpolymers used in embodiments of the invention have a M_(w)/M_(n) from 1.7 to 3.5 and at least one melting point, T_(m), in degrees Celsius and density, d, in grams/cubic centimeter, wherein the numerical values of the variables correspond to the relationship:

T _(m)>−2002.9+4538.5(d)−2422.2(d)², and preferably

T _(m)≥−6288.1+13141(d)−6720.3(d)², and more preferably

T _(m)≥858.91−1825.3(d)+1112.8(d)².

Such melting point/density relationship is illustrated in the FIG. 1. Unlike the traditional random copolymers of ethylene/α-olefins whose melting points decrease with decreasing densities, the interpolymers (represented by diamonds) exhibit melting points substantially independent of the density, particularly when density is between 0.87 g/cc to 0.95 g/cc. For example, the melting point of such polymers are in the range of 110° C. to 130° C. when density ranges from 0.875 g/cc to 0.945 g/cc. In some embodiments, the melting point of such polymers are in the range of 115° C. to 125° C. when density ranges from 0.875 g/cc to 0.945 g/cc.

In another aspect, the ethylene/α-olefin interpolymers comprise, in polymerized form, ethylene and one or more α-olefins and are characterized by a ΔT, in degree Celsius, defined as the temperature for the tallest Differential Scanning Calorimetry (“DSC”) peak minus the temperature for the tallest Crystallization Analysis Fractionation (“CRYSTAF”) peak and a heat of fusion in J/g, ΔH, and ΔT and ΔH satisfy the following relationships:

ΔT>−0.1299(ΔH)+62.81, and preferably

ΔT≥−0.1299(ΔH)+64.38, and more preferably

ΔT≥−0.1299(ΔH)+65.95,

for ΔH up to 130 J/g. Moreover, ΔT is equal to or greater than 48° C. for ΔH greater than 130 J/g. The CRYSTAF peak is determined using at least 5 percent of the cumulative polymer (that is, it is desirable for the peak to represent at least 5 percent of the cumulative polymer), and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30° C., and ΔH is the numerical value of the heat of fusion in J/g. More preferably, the highest CRYSTAF peak contains at least 10 percent of the cumulative polymer.

In yet another aspect, the ethylene/α-olefin interpolymers have a molecular fraction which elutes between 40° C. and 130° C. when fractionated using Temperature Rising Elution Fractionation (“TREF”), characterized in that said fraction has a molar comonomer content higher, preferably at least 5 percent higher, more preferably at least 10 percent higher, than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein the comparable random ethylene interpolymer contains the same comonomer(s), and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the block interpolymer. Preferably, the Mw/Mn of the comparable interpolymer is also within 10 percent of that of the block interpolymer and/or the comparable inter polymer has a total comonomer content within 10 weight percent of that of the block interpolymer.

In still another aspect, the ethylene/α-olefin interpolymers are characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured on a compression-molded film of an ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:

Re>1481-1629(d); and preferably

Re≥1491-1629(d); and more preferably

Re≥1501-1629(d); and even more preferably

Re≥1511-1629(d).

In some embodiments, the ethylene/α-olefin interpolymers have a tensile strength above 10 MPa, preferably a tensile strength≥11 MPa, more preferably a tensile strength≥13 MPa and/or an elongation at break of at least 600 percent, more preferably at least 700 percent, highly preferably at least 800 percent, and most highly preferably at least 900 percent at a crosshead separation rate of 11 cm/minute.

In other embodiments, the ethylene/α-olefin interpolymers have (1) a storage modulus ratio, G′(25° C.)/G′(100° C.), of from 1 to 50, preferably from 1 to 20, more preferably from 1 to 10; and/or (2) a 70° C. compression set of less than 80 percent, preferably less than 70 percent, especially less than 60 percent, less than 50 percent, or less than 40 percent, down to a compression set of zero percent.

In still other embodiments, the ethylene/α-olefin interpolymers have a 70° C. compression set of less than 80 percent, less than 70 percent, less than 60 percent, or less than 50 percent. Preferably, the 70° C. compression set of the interpolymers is less than 40 percent, less than 30 percent, less than 20 percent, and may go down to 0 percent.

In some embodiments, the ethylene/α-olefin interpolymers have a heat of fusion of less than 85 J/g and/or a pellet blocking strength of equal to or less than 100 pounds/foot² (4800 Pa), preferably equal to or less than 50 lbs/ft² (2400 Pa), especially equal to or less than 5 lbs/ft² (240 Pa), and as low as 0 lbs/ft² (0 Pa).

In other embodiments, the ethylene/α-olefin interpolymers comprise, in polymerized form, at least 50 mole percent ethylene and have a 70° C. compression set of less than 80 percent, preferably less than 70 percent or less than 60 percent, most preferably less than 40 to 50 percent and down to close zero percent.

In some embodiments, the multi-block copolymers possess a polydispersity index (PDI) fitting a Schultz-Flory distribution rather than a Poisson distribution. The copolymers are further characterized as having both a polydisperse block distribution and a polydisperse distribution of block sizes and possessing a most probable distribution of block lengths. Preferred multi-block copolymers are those containing 4 or more blocks or segments including terminal blocks. More preferably, the copolymers include at least 5, 10 or 20 blocks or segments including terminal blocks.

Comonomer content may be measured using any suitable technique, with techniques based on nuclear magnetic resonance (“NMR”) spectroscopy preferred. Moreover, for polymers or blends of polymers having relatively broad TREF curves, the polymer desirably is first fractionated using TREF into fractions each having an eluted temperature range of 10° C. or less. That is, each eluted fraction has a collection temperature window of 10° C. or less. Using this technique, said block interpolymers have at least one such fraction having a higher molar comonomer content than a corresponding fraction of the comparable interpolymer.

In another aspect, the polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks (i.e., at least two blocks) or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi-block copolymer, said block interpolymer having a peak (but not just a molecular fraction) which elutes between 40° C. and 130° C. (but without collecting and/or isolating individual fractions), characterized in that said peak, has a comonomer content estimated by infra-red spectroscopy when expanded using a full width/half maximum (FWHM) area calculation, has an average molar comonomer content higher, preferably at least 5 percent higher, more preferably at least 10 percent higher, than that of a comparable random ethylene interpolymer peak at the same elution temperature and expanded using a full width/half maximum (FWHM) area calculation, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the blocked interpolymer. Preferably, the Mw/Mn of the comparable interpolymer is also within 10 percent of that of the blocked interpolymer and/or the comparable interpolymer has a total comonomer content within 10 weight percent of that of the blocked interpolymer. The full width/half maximum (FWHM) calculation is based on the ratio of methyl to methylene response area [CH₃/CH₂] from the ATREF infra-red detector, wherein the tallest (highest) peak is identified from the base line, and then the FWHM area is determined. For a distribution measured using an ATREF peak, the FWHM area is defined as the area under the curve between T₁ and T₂, where T₁ and T₂ are points determined, to the left and right of the ATREF peak, by dividing the peak height by two, and then drawing a line horizontal to the base line, that intersects the left and right portions of the ATREF curve. A calibration curve for comonomer content is made using random ethylene/α-olefin copolymers, plotting comonomer content from NMR versus FWHM area ratio of the TREF peak. For this infra-red method, the calibration curve is generated for the same comonomer type of interest. The comonomer content of TREF peak of the polymer can be determined by referencing this calibration curve using its FWHM methyl:methylene area ratio [CH₃/CH₂] of the TREF peak.

Comonomer content may be measured using any suitable technique, with techniques based on nuclear magnetic resonance (NMR) spectroscopy preferred. Using this technique, said blocked interpolymers has higher molar comonomer content than a corresponding comparable interpolymer.

Preferably, for interpolymers of ethylene and 1-octene, the block interpolymer has a comonomer content of the TREF fraction eluting between 40 and 130° C. greater than or equal to the quantity (−0.2013)T+20.07, more preferably greater than or equal to the quantity (−0.2013)T+21.07, where T is the numerical value of the peak elution temperature of the TREF fraction being compared, measured in degrees Celsius.

In addition to the above aspects and properties described herein, the polymers can be characterized by one or more additional characteristics. In one aspect, the polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi-block copolymer, said block interpolymer having a molecular fraction which elutes between 40° C. and 130° C., when fractionated using TREF increments, characterized in that said fraction has a molar comonomer content higher, preferably at least 5 percent higher, more preferably at least 10, 15, 20 or 25 percent higher, than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer comprises the same comonomer(s), preferably it is the same comonomer(s), and a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the blocked interpolymer. Preferably, the Mw/Mn of the comparable interpolymer is also within 10 percent of that of the blocked interpolymer and/or the comparable interpolymer has a total comonomer content within 10 weight percent of that of the blocked interpolymer.

Preferably, the above interpolymers are interpolymers of ethylene and at least one α-olefin especially those interpolymers having a whole polymer density from 0.855 to 0.935 g/cm³, and more especially for polymers having more than 1 mole percent comonomer, the blocked interpolymer has a comonomer content of the TREF fraction eluting between 40 and 130° C. greater than or equal to the quantity (−0.1356)T+13.89, more preferably greater than or equal to the quantity (−0.1356)T+14.93, and most preferably greater than or equal to the quantity (−0.2013)T+21.07, where T is the numerical value of the peak ATREF elution temperature of the TREF fraction being compared, measured in degrees Celsius.

Preferably, for the above interpolymers of ethylene and at least one alpha-olefin especially those interpolymers having a whole polymer density from 0.855 to 0.935 g/cm³, and more especially for polymers having more than 1 mole percent comonomer, the blocked interpolymer has a comonomer content of the TREF fraction eluting between 40 and 130° C. greater than or equal to the quantity (−0.2013)T+20.07, more preferably greater than or equal to the quantity (−0.2013)T+21.07, where T is the numerical value of the peak elution temperature of the TREF fraction being compared, measured in degrees Celsius.

In still another aspect, the polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi-block copolymer, said block interpolymer having a molecular fraction which elutes between 40° C. and 130° C., when fractionated using TREF increments, characterized in that every fraction having a comonomer content of at least 6 mole percent, has a melting point greater than 100° C. For those fractions having a comonomer content from 3 mole percent to 6 mole percent, every fraction has a DSC melting point of 110° C. or higher. More preferably, said polymer fractions, having at least 1 mol percent comonomer, has a DSC melting point that corresponds to the equation:

Tm≥(−5.5926)(mol percent comonomer in the fraction)+135.90.

In yet another aspect, the polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi-block copolymer, said block interpolymer having a molecular fraction which elutes between 40° C. and 130° C., when fractionated using TREF increments, characterized in that every fraction that has an ATREF elution temperature greater than or equal to 76° C., has a melt enthalpy (heat of fusion) as measured by DSC, corresponding to the equation:

Heat of fusion (J/gm)≤(3.1718)(ATREF elution temperature in Celsius)−136.58,

The block interpolymers have a molecular fraction which elutes between 40° C. and 130° C., when fractionated using TREF increments, characterized in that every fraction that has an ATREF elution temperature between 40° C. and less than 76° C., has a melt enthalpy (heat of fusion) as measured by DSC, corresponding to the equation:

Heat of fusion (J/gm)≤(1.1312)(ATREF elution temperature in Celsius)+22.97.

The comonomer composition of the TREF peak can be measured using an IR4 infra-red detector available from Polymer Char, Valencia, Spain (http://www.polymerchar.com/).

The “composition mode” of the detector is equipped with a measurement sensor (CH₂) and composition sensor (CH₃) that are fixed narrow band infra-red filters in the region of 2800-3000 cm⁻¹. The measurement sensor detects the methylene (CH₂) carbons on the polymer (which directly relates to the polymer concentration in solution) while the composition sensor detects the methyl (CH₃) groups of the polymer. The mathematical ratio of the composition signal (CH₃) divided by the measurement signal (CH₂) is sensitive to the comonomer content of the measured polymer in solution and its response is calibrated with known ethylene alpha-olefin copolymer standards.

The detector when used with an ATREF instrument provides both a concentration (CH₂) and composition (CH₃) signal response of the eluted polymer during the TREF process. A polymer specific calibration can be created by measuring the area ratio of the CH₃ to CH₂ for polymers with known comonomer content (preferably measured by NMR). The comonomer content of an ATREF peak of a polymer can be estimated by applying the reference calibration of the ratio of the areas for the individual CH₃ and CH₂ response (i.e., area ratio CH₃/CH₂ versus comonomer content).

The area of the peaks can be calculated using a full width/half maximum (FWHM) calculation after applying the appropriate baselines to integrate the individual signal responses from the TREF chromatogram. The full width/half maximum calculation is based on the ratio of methyl to methylene response area [CH₃/CH₂] from the ATREF infra-red detector, wherein the tallest (highest) peak is identified from the base line, and then the FWHM area is determined. For a distribution measured using an ATREF peak, the FWHM area is defined as the area under the curve between T1 and T2, where T1 and T2 are points determined, to the left and right of the ATREF peak, by dividing the peak height by two, and then drawing a line horizontal to the base line, that intersects the left and right portions of the ATREF curve.

The application of infra-red spectroscopy to measure the comonomer content of polymers in this ATREF-infra-red method is, in principle, similar to that of GPC/FTIR systems as described in the following references: Markovich, Ronald P.; Hazlitt, Lonnie G.; Smith, Linley; “Development of gel-permeation chromatography-Fourier transform infrared spectroscopy for characterization of ethylene-based polyolefin copolymers”. Polymeric Materials Science and Engineering (1991), 65, 98-100.; and Deslauriers, P. J.; Rohlfing, D. C.; Shieh, E. T.; “Quantifying short chain branching microstructures in ethylene-1-olefin copolymers using size exclusion chromatography and Fourier transform infrared spectroscopy (SEC-FTIR)”. Polymer (2002), 43, 59-170., both of which are incorporated by reference herein in their entirety.

In other embodiments, the ethylene/α-olefin interpolymer is characterized by an average block index, ABI, which is greater than zero and up to 1.0 and a molecular weight distribution, M_(W)/M_(n), greater than 1.3. The average block index, ABI, is the weight average of the block index (“BI”) for each of the polymer fractions obtained in preparative TREF from 20° C. and 110° C., with an increment of 5° C.:

ABI=Σ(w _(i) BI _(i))

where BI_(i) is the block index for the ith fraction of the ethylene/α-olefin interpolymer obtained in preparative TREF, and w_(i) is the weight percentage of the i^(th) fraction.

For each polymer fraction, BI is defined by one of the two following equations (both of which give the same BI value):

${BI} = {{\frac{{1/T_{X}} - {1/T_{XO}}}{{1/T_{A}} - {1/T_{AB}}}\mspace{14mu}{or}\mspace{14mu}{BI}} = {- \frac{{LnP}_{X} - {LnP}_{XO}}{{LnP}_{A} - {LnP}_{AB}}}}$

where T_(X) is the preparative ATREF elution temperature for the i^(th) fraction (preferably expressed in Kelvin), P_(X) is the ethylene mole fraction for the i^(th) fraction, which can be measured by NMR or IR as described above. P_(AB) is the ethylene mole fraction of the whole ethylene/α-olefin interpolymer (before fractionation), which also can be measured by NMR or IR. T_(A) and P_(A) are the ATREF elution temperature and the ethylene mole fraction for pure “hard segments” (which refer to the crystalline segments of the interpolymer). As a first order approximation, the T_(A) and P_(A) values are set to those for high density polyethylene homopolymer, if the actual values for the “hard segments” are not available. For calculations performed herein, T_(A) is 372° K, P_(A) is 1.

T_(AB) is the ATREF temperature for a random copolymer of the same composition and having an ethylene mole fraction of P_(AB). T_(AB) can be calculated from the following equation:

LnP _(AB) =α/T _(AB) +β

where α and β are two constants which can be determined by calibration using a number of known random ethylene copolymers. It should be noted that α and β may vary from instrument to instrument. Moreover, one would need to create their own calibration curve with the polymer composition of interest and also in a similar molecular weight range as the fractions. There is a slight molecular weight effect. If the calibration curve is obtained from similar molecular weight ranges, such effect would be essentially negligible. In some embodiments, random ethylene copolymers satisfy the following relationship:

LnP=−237.83/T _(ATREF)+0.639

T_(XO) is the ATREF temperature for a random copolymer of the same composition and having an ethylene mole fraction of P_(X). T_(XO) can be calculated from LnP_(X)=α/T_(XO)+β. Conversely, P_(XO) is the ethylene mole fraction fora random copolymer of the same composition and having an ATREF temperature of T_(X), which can be calculated from Ln P_(XO)=α/T_(X)=β.

Once the block index (BI) for each preparative TREF fraction is obtained, the weight average block index, ABI, for the whole polymer can be calculated. In some embodiments, ABI is greater than zero but less than 0.3 or from 0.1 to 0.3. In other embodiments, ABI is greater than 0.3 and up to 1.0. Preferably, ABI should be in the range of from 0.4 to 0.7, from 0.5 to 0.7, or from 0.6 to 0.9. In some embodiments, ABI is in the range of from 0.3 to 0.9, from 0.3 to 0.8, or from 0.3 to 0.7, from 0.3 to 0.6. from 0.3 to 0.5, or from 0.3 to 0.4. In other embodiments, ABI is in the range of from 0.4 to 1.0. from 0.5 to 1.0, or from 0.6 to 1.0, from 0.7 to 1.0, from 0.8 to 1.0, or from 0.9 to 1.0.

Another characteristic of the ethylene/α-olefin interpolymer is that the ethylene/α-olefin interpolymer comprises at least one polymer fraction which can be obtained by preparative TREF, wherein the fraction has a block index greater than 0.1 and up to 1.0 and a molecular weight distribution, M_(w)M_(n), greater than 1.3. In some embodiments, the polymer fraction has a block index greater than 0.6 and up to 1.0. greater than 0.7 and up to 1.0. greater than 0.8 and up to 1.0, or greater than 0.9 and up to 1.0. In other embodiments, the polymer fraction has a block index greater than 0.1 and up to 1.0, greater than 0.2 and up to 1.0. greater than 0.3 and up to 1.0, greater than 0.4 and up to 1.0, or greater than 0.4 and up to 1.0. In still other embodiments, the polymer fraction has a block index greater than 0.1 and up to 0.5. greater than 0.2 and up to 0.5. greater than 0.3 and up to 0.5, or greater than 0.4 and up to 0.5. In yet other embodiments, the polymer fraction has a block index greater than 0.2 and up to 0.9, greater than 0.3 and up to 0.8, greater than 0.4 and up to 0.7, or greater than 0.5 and up to 0.6.

For copolymers of ethylene and an α-olefin, the polymers preferably possess (1) a PDI of at least 1.3, more preferably at least 1.5. at least 1.7, or at least 2.0, and most preferably at least 2.6, up to a maximum value of 5.0, more preferably up to a maximum of 3.5, and especially up to a maximum of 2.7; (2) a heat of fusion of 80 J/g or less; (3) an ethylene content of at least 50 weight percent; (4) a glass transition temperature, T_(g), of less than −25° C., more preferably less than −30° C., and/or (5) one and only one T_(m).

Further, the polymers can have, alone or in combination with any other properties disclosed herein, a storage modulus, G′, such that log (G′) is greater than or equal to 400 kPa. preferably greater than or equal to 1.0 MPa, at a temperature of 100° C. Moreover, the polymers possess a relatively flat storage modulus as a function of temperature in the range from 0 to 100° C. that is characteristic of block copolymers, and heretofore unknown for an olefin copolymer, especially a copolymer of ethylene and one or more C₃₋₈ aliphatic α-olefins. By the term “relatively flat” in this context is meant that log G′ (in Pascals) decreases by less than one order of magnitude between 50 and 100° C. preferably between 0 and 100° C.

The interpolymers may be further characterized by a thermomechanical analysis penetration depth of 1 mm at a temperature of at least 90° C. as well as a flexural modulus of from 3 kpsi (20 MPa) to 13 kpsi (90 MPa). Alternatively, the interpolymers can have a thermomechanical analysis penetration depth of 1 mm at a temperature of at least 104° C. as well as a flexural modulus of at least 3 kpsi (20 MPa). They may be characterized as having an abrasion resistance (or volume loss) of less than 90 mm³. The polymers have significantly better flexibility-heat resistance balance than the other polymers.

Additionally, the ethylene/α-olefin interpolymers can have a melt index, I₂, from 0.01 to 2000 g/10 minutes, preferably from 0.01 to 1000 g/10 minutes. more preferably from 0.01 to 500 g/10 minutes, and especially from 0.01 to 100 g/10 minutes. In certain embodiments, the ethylene/α-olefin interpolymers have a melt index, I₂ from 0.01 to 10 g/10 minutes, from 0.5 to 50 g/10 minutes, from 1 to 30 g/10 minutes, from 1 to 6 g/10 minutes or from 0.3 to 10 g/10 minutes. In certain embodiments, the melt index for the ethylene/α-olefin polymers is 1 g/10 minutes, 3 g/10 minutes or 5 g/10 minutes.

The polymers can have molecular weights, M_(w), from 1,000 g/mole to 5,000,000 g/mole, preferably from 1000 g/mole to 1,000,000, more preferably from 10,000 g/mole to 500,000 g/mole, and especially from 10,000 g/mole to 300,000 g/mole. The density of the polymers can be from 0.80 to 0.99 g/cm³ and preferably for ethylene containing polymers from 0.85 g/cm³ to 0.97 g/cm³. In certain embodiments, the density of the ethylene/α-olefin polymers ranges from 0.860 to 0.925 g/cm³ or 0.867 to 0.910 g/cm³.

The process of making the polymers has been disclosed in the following patent applications: U.S. Provisional Application No. 60/553,906, filed Mar. 17, 2004; U.S. Provisional Application No. 60/662,937, filed Mar. 17, 2005; U.S. Provisional Application No. 60/662,939, filed Mar. 17, 2005; U.S. Provisional Application No. 60/5662938, filed Mar. 17, 2005; PCT Application No. PCT/US2005/008916, tiled Mar. 17, 2005; PCT Application No. PCT/US2005/008915, filed Mar. 17, 2005; and PCT Application No. PCT/US2005/008917, filed Mar. 17, 2005, all of which are incorporated by reference herein in their entirety.

The interpolymers also exhibit a unique crystallization and branching distribution relationship. That is, the interpolymers have a relatively large difference between the tallest peak temperature measured using CRYSTAF and DSC as a function of heat of fusion, especially as compared to random copolymers containing the same monomers and monomer level or physical blends of polymers, such as a blend of a high density polymer and a lower density copolymer, at equivalent overall density. It is believed that this unique feature of the interpolymers is due to the unique distribution of the comonomer in blocks within the polymer backbone. In particular, the interpolymers may comprise alternating blocks of differing comonomer content (including homopolymer blocks). The interpolymers may also comprise a distribution in number and/or block size of polymer blocks of differing density or comonomer content, which is a Schultz-Flory type of distribution. In addition, the interpolymers also have a unique peak melting point and crystallization temperature profile that is substantially independent of polymer density, modulus, and morphology. In a preferred embodiment, the microcrystalline order of the polymers demonstrates characteristic spherulites and lamellae that are distinguishable from random or block copolymers, even at PDI values that are less than 1.7, or even less than 1.5, down to less than 1.3.

Moreover, the interpolymers may be prepared using techniques to influence the degree or level of blockiness. That is the amount of comonomer and length of each polymer block or segment can be altered by controlling the ratio and type of catalysts and shuttling agent as well as the temperature of the polymerization, and other polymerization variables. A surprising benefit of this phenomenon is the discovery that as the degree of blockiness is increased, the optical properties, tear strength, and high temperature recovery properties of the resulting polymer are improved. In particular, haze decreases while clarity, tear strength, and high temperature recovery properties increase as the average number of blocks in the polymer increases. By selecting shuttling agents and catalyst combinations having the desired chain transferring ability (high rates of shuttling with low levels of chain termination) other forms of polymer termination are effectively suppressed. Accordingly, little if any β-hydride elimination is observed in the polymerization of ethylene/α-olefin comonomer mixtures according to embodiments of the invention, and the resulting crystalline blocks are highly, or substantially completely, linear, possessing little or no long chain branching.

Polymers with highly crystalline chain ends can be selectively prepared in accordance with embodiments of the invention. In elastomer applications, reducing the relative quantity of polymer that terminates with an amorphous block reduces the intermolecular dilutive effect on crystalline regions. This result can be obtained by choosing chain shuttling agents and catalysts having an appropriate response to hydrogen or other chain terminating agents. Specifically, if the catalyst which produces highly crystalline polymer is more susceptible to chain termination (such as by use of hydrogen) than the catalyst responsible for producing the less crystalline polymer segment (such as through higher comonomer incorporation, regio-regular or atactic polymer formation), then the highly crystalline polymer segments will preferentially populate the terminal portions of the polymer. Not only are the resulting terminated groups crystalline, but upon termination, the highly crystalline polymer forming catalyst site is once again available for reinitiation of polymer formation. The initially formed polymer is therefore another highly crystalline polymer segment. Accordingly, both ends of the resulting multi-block copolymer are preferentially highly crystalline.

The ethylene α-olefin interpolymers used in some embodiments are preferably interpolymers of ethylene with at least one C₃-C₂₀ α-olefin. Copolymers of ethylene and a C₃C₂₀ α-olefin are especially preferred. The interpolymers may further comprise C₄-C₁₈ diolefin and/or alkenylbenzene. Suitable unsaturated comonomers useful for polymerizing with ethylene include, for example, ethylenically unsaturated monomers, conjugated or nonconjugated dienes, polyenes, alkenylbenzenes, and the like. Examples of such comonomers include C₃-C₂₀ α-olefins such as propylene, isobutylene, 1-butene, 1-hexene, 1-pentene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene, 1-decene, and the like. 1-Butene and 1-octene are especially preferred. Other suitable monomers include styrene, halo- or alkyl-substituted styrenes, vinylbenzocyclobutane, 1,4-hexadiene, 1,7-octadiene, and naphthenics (e.g., cyclopentene, cyclohexene and cyclooctene).

While ethylene/α-olefin interpolymers are preferred polymers, other ethylene/olefin polymers may also be used. Olefins as used herein refer to a family of unsaturated hydrocarbon-based compounds with at least one carbon-carbon double bond. Depending on the selection of catalysts, any olefin may be used in embodiments of the invention. Preferably, suitable olefins are C₃-C₂₀ aliphatic and aromatic compounds containing vinylic unsaturation, as well as cyclic compounds, such as cyclobutene, cyclopentene, dicyclopentadiene, and norbornene, including but not limited to, norbornene substituted in the 5 and 6 position with C₁-C₂₀ hydrocarbyl or cyclohydrocarbyl groups. Also included are mixtures of such olefins as well as mixtures of such olefins with C₄-C₄₀ diolefin compounds.

Examples of olefin monomers include, but are not limited to propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene, 3-methyl-1-butene, 3-methyl-1-pentene, 4-methyl-1-pentene, 4,6-dimethyl-1-heptene, 4-vinylcyclohexene, vinylcyclohexane, norbornadiene, ethylidene norbornene, cyclopentene, cyclohexene, dicyclopentadiene, cyclooctene, C₄-C₄₀ dienes, including but not limited to 1,3-butadiene, 1,3-pentadiene, 1,4-hexadiene, 1,5-hexadiene, 1,7-octadiene, 1,9-decadiene, other C₄-C₄₀ α-olefins, and the like. In certain embodiments, the α-olefin is propylene, 1-butene, 1-pentene, 1-hexene, 1-octene or a combination thereof. Although any hydrocarbon containing a vinyl group potentially may be used in embodiments of the invention, practical issues such as monomer availability, cost, and the ability to conveniently remove unreacted monomer from the resulting polymer may become more problematic as the molecular weight of the monomer becomes too high.

The polymerization processes described herein are well suited for the production of olefin polymers comprising monovinylidene aromatic monomers including styrene, o-methyl styrene, p-methyl styrene, t-butylstyrene, and the like. In particular, interpolymers comprising ethylene and styrene can be prepared by following the teachings herein. Optionally, copolymers comprising ethylene, styrene and a C₃-C₂₀ alpha olefin, optionally comprising a C₄-C₂₀ diene, having improved properties can be prepared.

Suitable non-conjugated diene monomers can be a straight chain, branched chain or cyclic hydrocarbon diene having from 6 to 15 carbon atoms. Examples of suitable non-conjugated dienes include, but are not limited to, straight chain acyclic dienes, such as 1,4-hexadiene, 1,6-octadiene, 1,7-octadiene, 1,9-decadiene, branched chain acyclic dienes, such as 5-methyl-1,4-hexadiene; 3,7-dimethyl-1,6-octadiene; 3,7-dimethyl-1,7-octadiene and mixed isomers of dihydromyricene and dihydroocinene, single ring alicyclic dienes, such as 1,3-cyclopentadiene; 1,4-cyclohexadiene; 1,5-cyclooctadiene and 1,5-cyclododecadiene, and multi-ring alicyclic fused and bridged ring dienes, such as tetrahydroindene, methyl tetrahydroindene, dicyclopentadiene, bicyclo-(2,2,1)-hepta-2,5-diene; alkenyl, alkylidene, cycloalkenyl and cycloalkylidene norbornenes, such as 5-methylene-2-norbornene (MNB); 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5-(4-cyclopentenyl)-2-norbornene, 5-cyclohexylidene-2-norbornene, 5-vinyl-2-norbornene, and norbornadiene. Of the dienes typically used to prepare EPDMs, the particularly preferred dienes are 1,4-hexadiene (HD), 5-ethylidene-2-norbornene (ENB), 5-vinylidene-2-norbornene (VNB), 5-methylene-2-norbornene (MNB), and dicyclopentadiene (DCPD). The especially preferred dienes are 5-ethylidene-2-norbornene (ENB) and 1,4-hexadiene (HD).

One class of desirable polymers that can be made in accordance with embodiments of the invention are elastomeric interpolymers of ethylene, a C₃-C₂₀ α-olefin, especially propylene, and optionally one or more diene monomers. Preferred α-olefins for use in this embodiment of the present invention are designated by the formula CH₂=CHR*, where R* is a linear or branched alkyl group of from 1 to 12 carbon atoms. Examples of suitable α-olefins include, but are not limited to, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, and 1-octene. A particularly preferred α-olefin is propylene. The propylene based polymers are generally referred to in the art as EP or EPDM polymers. Suitable dienes for use in preparing such polymers, especially multi-block EPDM type polymers include conjugated or non-conjugated, straight or branched chain-, cyclic- or polycyclic-dienes comprising from 4 to 20 carbons. Preferred dienes include 1,4-pentadiene, 1,4-hexadiene, 5-ethylidene-2-norbornene, dicyclopentadiene, cyclohexadiene, and 5-butylidene-2-norbornene. A particularly preferred diene is 5-ethylidene-2-norbornene.

Because the diene containing polymers comprise alternating segments or blocks containing greater or lesser quantities of the diene (including none) and α-olefin (including none), the total quantity of diene and α-olefin may be reduced without loss of subsequent polymer properties. That is, because the diene and α-olefin monomers are preferentially incorporated into one type of block of the polymer rather than uniformly or randomly throughout the polymer, they are more efficiently utilized and subsequently the crosslink density of the polymer can be better controlled. Such crosslinkable elastomers and the cured products have advantaged properties, including higher tensile strength and better elastic recovery.

In some embodiments, the interpolymers made with two catalysts incorporating differing quantities of comonomer have a weight ratio of blocks formed thereby from 95:5 to 5:95. The elastomeric polymers desirably have an ethylene content of from 20 to 90 percent, a diene content of from 0.1 to 10 percent, and an α-olefin content of from 10 to 80 percent, based on the total weight of the polymer. Further preferably, the multi-block elastomeric polymers have an ethylene content of from 60 to 90 percent, a diene content of from 0.1 to 10 percent, and an α-olefin content of from 10 to 40 percent, based on the total weight of the polymer. Preferred polymers are high molecular weight polymers, having a weight average molecular weight (Mw) from 10,000 to 2,500,000, preferably from 20,000 to 500,000, more preferably from 20,000 to 350,000, and a polydispersity less than 3.5, more preferably less than 3.0, and a Mooney viscosity (ML (1+4) 125° C.) from 1 to 250. More preferably, such polymers have an ethylene content from 65 to 75 percent, a diene content from 0 to 6 percent, and an α-olefin content from 20 to 35 percent.

The ethylene/α-olefin interpolymers can be functionalized by incorporating at least one functional group in its polymer structure. Exemplary functional groups may include, for example, ethylenically unsaturated mono- and di-functional carboxylic acids, ethylenically unsaturated mono- and di-functional carboxylic acid anhydrides, salts thereof and esters thereof. Such functional groups may be grafted to an ethylene/α-olefin interpolymer, or it may be copolymerized with ethylene and an optional additional comonomer to form an interpolymer of ethylene, the functional comonomer and optionally other comonomer(s). Means for grafting functional groups onto polyethylene are described for example in U.S. Pat. Nos. 4,762,890, 4,927,888, and 4,950,541, the disclosures of these patents are incorporated herein by reference in their entirety. One particularly useful functional group is malic anhydride.

The amount of the functional groups present in the functional interpolymer can vary. The functional group can typically be present in a copolymer-type functionalized interpolymer in an amount of at least 1.0 weight percent, preferably at least 5 weight percent, and more preferably at least 7 weight percent. The functional group will typically be present in a copolymer-type functionalized interpolymer in an amount less than 40 weight percent, preferably less than 30 weight percent, and more preferably less than 25 weight percent.

An exemplary olefin block copolymer comprises ethylene and octene. A commercially available olefin block copolymer that can be used in the foam is INFUSE™ from the Dow Chemical company.

Another exemplary ethylene for as an elastomer is homogeneously branched ethylene-α-olefin copolymers. These copolymers can be made with a single-site catalyst such as a metallocene catalyst or constrained geometry catalyst, and typically have a melting point of less than 105, specifically less than 90, more specifically less than 85, even more specifically less than 80 and still more specifically less than 75° C. The melting point is measured by differential scanning calorimetry (DSC) as described, for example, in U.S. Pat. No. 5,783,638. The α-olefin is preferably a C₃₋₂₀ linear, branched or cyclic α-olefin. Examples of C₃₋₂₀ α-olefins include propene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, and 1-octadecene. The α-olefins can also contain a cyclic structure such as cyclohexane or cyclopentane, resulting in an α-olefin such as 3-cyclohexyl-1-propene (allyl cyclohexane) and vinyl cyclohexane.

Illustrative homogeneously branched ethylene-α-olefin copolymers include ethylene/propylene, ethylene/butene, ethylene/1-hexene, ethylene/1-octene, ethylene/styrene, and the like. Illustrative terpolymers include ethylene/propylene/1-octene, ethylene/propylene/butene, ethylene/butene/1-octene, and ethylene/butene/styrene. The copolymers can be random copolymers or block copolymers.

Examples of commercially available homogeneously branched ethylene-α-olefin interpolymers include homogeneously branched, linear ethylene-α-olefin copolymers (e.g. TAFMER™ by Mitsui Petrochemicals Company Limited and EXACT™ by Exxon Chemical Company), and the homogeneously branched, substantially linear ethylene-α-olefin polymers (e.g., AFFINITY™ and ENGAGE™ polyethylene available from the Dow Chemical Company).

The elastomer (i.e., the ethylene/α-olefin interpolymer) may be used in the foamable composition in an amount of 60 to 90 wt %, preferably 70 to 88 wt %, and more preferably 80 to 85 wt %, based on the total weight of the foamable composition.

The composition also comprises a carboxylated olefin copolymer that is not neutralized. In other words, the acid functionality in the carboxylated olefin copolymer is not neutralized with a metal ion. The unneutralized carboxylated olefin copolymer plays a useful role in controlling cell size. The carboxylated olefin copolymer is not covalently or ionically bonded to the elastomer (the olefin block or random copolymer) prior to conducting the crosslinking reaction.

The carboxylated olefin copolymer comprises an ethylene polymer that has grafted thereto (or copolymerized thereto) an unsaturated carboxylic acid or an anhydride, ester, amide, or imide, hereafter designated as “grafting compound”. The grafting compound preferably is an aliphatic unsaturated dicarboxylic add or an anhydride. The carboxylic acid preferably contains up to 4, preferably up to 5, and more preferably up to 6 carbon atoms. Examples of unsaturated carboxylic acids are maleic acid, fumaric acid, itaconic add, acrylic acid, methacrylic acid, crotonic acid, and citraconic acid. Examples of derivatives of unsaturated carboxylic acids are maleic anhydride, citraconic anhydride, itaconic anhydride, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, glycidyl acrylate, glycidyl methacrylate, monoethyl maleate, diethyl maleate, monomethyl fumarate, dimethyl fumarate, monomethyl itaconate, diethyl itaconate, acrylamide, methacrylamide, monomaleamide, dimaleamide, N,N-diethylmaleamide, N-monobutylmaleamide, N,N-dibutylmaleamide, monofumaramide, difumaramide, N-monoethylfumaramide, N,N-diethylfumaramide, N-monobutylfumaramide, N,N-dibutyl fumaramide, maleimide, N-butylmaleimide, N-phenylmaleimide, sodium acrylate, sodium methacrylate, potassium acrylate, and potassium methacrylate.

Examples of carboxylated olefin copolymer include ethylene/(meth)acrylic acid copolymers, ethylene/(meth)acrylic acid/n-butyl(meth)acrylate copolymers, ethylene/(meth)acrylic acid/iso-butyl(meth)acrylate copolymers, ethylene/(meth)acrylic acid/tert-butyl(meth)acrylate copolymers, ethylene/(meth)acrylic acid/methyl(meth)acrylate copolymers, ethylene/(meth)acrylic acid/ethyl(meth)acrylate copolymers, ethylene/maleic acid and ethylene/maleic acid monoester copolymers, ethylene/maleic acid monoester/n-butyl(meth)acrylate copolymers, ethylene/maleic acid monoester/methyl(meth)acrylate copolymers, ethylene/maleic acid monoester/ethyl(meth)acrylate copolymers, or combinations of two or more thereof.

One or more, preferably one, grafting compound is grafted onto the ethylene polymer. Maleic anhydride is the preferred grafting compound. An exemplary unsaturated carboxylic acid is acrylic acid or methacrylic acid. In an embodiment, ethylene/(meth)acrylic acid copolymers are preferred.

The graft process can be initiated by decomposing initiators to form free radicals, including azo-containing compounds, carboxylic peroxyacids and peroxyesters, alkyl hydroperoxides, and dialkyl and diacyl peroxides, among others. Many of these compounds and their properties have been described (Reference: J. Branderup, E. Immergut, E. Grulke, eds. “Polymer Handbook,” 4th ed., Wiley, New York, 1999, Section II, pp. 1-76.). Alternatively, the grafting compound can be copolymerized with ethylene by typical tubular and autoclave processes.

The grafted ethylene polymer, as well as the ethylene polymer which is used for grafting, is selected from ultralow density polyethylene (ULDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), high melt strength high density polyethylene (HMS-HDPE), ultrahigh density polyethylene (UHDPE), or combinations thereof.

In an embodiment, the grafted ethylene polymer, as well as the ethylene polymer which is used for grafting, preferably have a density of up to 0.94 g/cm³, more preferably from 0.850 to 0.935 g/cm³, most preferably from 0.860 to 0.930 g/cm³, particularly from 0.865 to 0.930 g/cm³. However, it is to be understood that the polymer density changes slightly upon grafting. In the case of ethylene polymers, it has been found that the polymer density is important for providing a printer with sufficient mechanical strength and flexibility and for achieving a sufficient solubility of the grafted ethylene polymer in the organic solvent.

The carboxylated olefin copolymer has a melt index of less than or equal to 5 g/10 minutes, preferably less than or equal to 4 g/10 minutes, and more preferably less than or equal to 3 g/10 minutes when measured at 2.16 kg and 190° C. as per ASTM D 1238. In an embodiment, the carboxylated olefin copolymer has a melt index of greater than or equal to 1 g/10 minutes when measured at 2.16 kg and 190° C. as per ASTM D 1238.

Examples of carboxylated olefin copolymers are PRIMACOR™ an ethylene-methacrylic acid copolymer commercially available from The Dow Chemical Company or NUCREL® commercially available from the DuPont Chemical Company. The carboxylated olefin copolymer used here is an ethylene methyl acrylic acid copolymer (E-MAA) with an amount of 3 to 20 wt %, preferably 4 to 15 wt % and more preferably 5 to 10 wt %, based on the total weight of the resin in the foamable composition.

The foamable composition also contains a crosslinking agent. Crosslinking agents include one or more organic peroxides including dialkyl peroxides, peroxy esters, peroxy dicarbonates, peroxy ketals, diacyl peroxides, or combinations of two or more thereof. Examples of peroxides include dicumyl peroxide (also known as α,α-Bis(tert-butylperoxy) diisopropylbenzene (BIPB)), di(3,3,5-trimethyl hexanoyl)peroxide, t-butyl peroxypivalate, t-butyl peroxyneodecanoate, di(sec-butyl)peroxydicarbonate, t-amyl peroxyneodecanoate, 1,1-di-t-butyl peroxy-3,3,5-trimethylcyclohexane, t-butyl-cumyl peroxide, 2,5-dimethyl-2,5-di(tertiary-butyl-peroxyl)hexane, 1,3-bis(tertiary-butyl-peroxyl-isopropyl)benzene, or a combination thereof. An exemplary crosslinking agent is dicumyl peroxide commercially available under the tradename LUPEROX® from Arkema, Peroximon® from Arkema or the tradename TRIGONOX® from Akzo Nobel.

The crosslinking agent is used in an amount of 0.05 to 10 wt %, preferably 0.3 to 5 wt % and more preferably 0.5 to 3 wt %, based on the total weight of the foamable composition.

The foamable composition may also contain a suitable blowing agent in order to generate porosity to form the foam upon heating. It is desirable to use blowing agents that decompose (to release gases) at around the same temperature that the crosslinking agent decomposes. This permits the formation of a foam with subsequent crosslinking that facilitates the retention of porosity in the foam. It is generally desirable to use blowing agents in an amount effective to produce a fairly uniform cell size in the foam. The blowing agent generally acts in conjunction with the curing agent to facilitate a uniform crosslink density as well as a uniform pore size in the foam. The blowing agents may be physical blowing agents or chemical blowing agents. Physical blowing agents are released from the composition as a result of binodal decomposition and expand during the blowing process to form the foam while chemical blowing agents decompose to liberate gases (e.g., azo compounds) during the blowing process to form a foam.

Physical blowing agents comprising hydrogen atom-containing components, may be used alone or as mixtures with each other or with another type of blowing agent (e.g., chemical blowing agents) such as azo compounds. The physical blowing agents may be selected from a broad range of materials, including hydrocarbons, ethers, esters and partially halogenated hydrocarbons (e.g., perfluorinated hydrocarbons), ethers and esters, and the like. The physical blowing agents may also include relatively inert gases such as nitrogen, argon, carbon dioxide, and the like. Typical physical blowing agents have a boiling point between −50° C. and 100° C., and preferably between −50° C. and 50° C. Among the usable hydrogen-containing blowing agents are the HCFC's (halo chlorofluorocarbons) such as 1,1-dichloro-1-fluoroethane, 1,1-dichloro-2,2,2-trifluoro-ethane, monochlorodifluoromethane, and 1-chloro-1,1-difluoroethane; the HFCs (halo fluorocarbons) such as 1,1,1,3,3,3-hexafluoropropane, 2,2,4,4-tetrafluorobutane, 1,1,1,3,3,3-hexafluoro-2-methylpropane, 1,1,1,3,3-pentafluoropropane, 1,1,1,2,2-pentafluoropropane, 1,1,1,2,3-pentafluoropropane, 1,1,2,3,3-pentafluoropropane, 1,1,2,2,3-pentafluoropropane, 1,1,1,3,3,4-hexafluorobutane, 1,1,1,3,3-pentafluorobutane, 1,1,1,4,4,4-hexafluorobutane, 1,1,1,4,4-pentafluorobutane, 1,1,2,2,3,3-hexafluoropropane, 1,1,1,2,3,3-hexafluoropropane, 1,1-difluoroethane, 1,1,1,2-tetrafluoroethane, and pentafluoroethane; the HFE's (halo fluoroethers) such as methyl-1,1,1-trifluoroethyl ether and difluoromethyl-1,1,1-trifluoroethyl ether; and the hydrocarbons such as n-pentane, isopentane, cyclopentane, or the like.

Gaseous non-CFC or non-HCFC physical blowing agents such as carbon dioxide, nitrogen, dinitroso-pentamethylene-tetramine, SF₆, nitrous oxide, argon, helium, noble gases, such as xenon, air (nitrogen and oxygen blend), and blends of these gases. The gases may be used as blowing agents in the gaseous state, a liquid state or in a supercritical state.

Chemical blowing agents include azobisisobutyronitrile (AIBN), azodicarbonamide, dinitroso-pentamethylene-tetramine, p-toluene sulfonyl hydrazide, p,p′-oxy-bis(benzenesulfonyl hydrazide), or combinations thereof may be used to produce the foam. An exemplary azo compound is azobisisobutyronitrile. In order to tailor expansion-decomposition temperature and foaming processes, a blowing agent may also be a mixture of blowing agents or of blowing agents and an activator.

The blowing agent is used in an amount of 0.1 to 10 wt %, preferably 1 to 5 wt % and more preferably 2 to 4 wt %, based on the total weight of the foamable composition.

The weight ratio of an unneutralized carboxylated olefin polymer to the blowing agent is generally reduced when compared with the weight ratio of a neutralized carboxylated olefin polymer to the blowing agent in order to arrive at the same foam density at which mechanical properties can be compared. In an embodiment, the weight ratio of an unneutralized carboxylated olefin polymer to the blowing agent is 0.01 to 4.0, preferably 0.2 to 3.0, and more preferably 1 to 2.

The foamable composition may also include 0.1 to 10 wt %, preferably 0.2 to 5 wt %, and more preferably 0.3 to 4 wt % of an activator to lower the decomposition temperature/profile of blowing agents. An activator can be one or more metal oxides, metal salts, metal hydroxides or organometallic complexes, or a combination thereof. Examples of activator are zinc oxide, zinc stearate, magnesium hydroxide, calcium carbonate, or the like, or a combination thereof. The activator may facilitate the neutralization of the carboxylic acid during the reaction to produce the foam. This may improve the compressive strength of the foam.

In an embodiment, the weight ratio of the activator to the carboxylated olefin copolymer is greater than or equal to 0.3, preferably greater than or equal to 0.4 and more preferably greater than or equal to 0.45. In an embodiment, the weight ratio of the activator to the carboxylated olefin copolymer is less than 0.8, preferably less than or equal to 0.77 and more preferably less than or equal to 0.75.

Other additives, which can be present in the composition from 0.1 to 20 or 2 to 12 wt % based on the total weight of the composition, may include, pigment (TiO₂ and other compatible colored pigments), adhesion promoter (to improve adhesion of the expanded foam to other materials), filler (e.g., calcium carbonate, barium sulfate, and/or silicon oxide), nucleating agent (pure form or concentrate form, e.g., CaCO₃, SiO₂, or combinations of two or more thereof, rubber (to improve rubber-like elasticity, such as natural rubber, SBR, polybutadiene, and/or ethylene propylene diene terpolymer), stabilizer (e.g., antioxidants, UV absorbers, and/or flame retardants), and processing aids (e.g., Octene R-130 manufactured by Octene Co., Taiwan). Antioxidant (modifying the organoleptic properties such as reducing odor or taste) can include phenolic antioxidants such as IRGANOX from Ciba Geigy Inc. (Tarrytown, N.Y.).

In an embodiment, the foamable composition may optionally contain a poly(ethylene vinylacetate) copolymer. The poly(ethylene vinylacetate) copolymer may have a melt index of 2 to 3 grams per 10 min (g/10 min) as measured per ASTM D 1238 and may contain the vinylacetatc (VA) in an amount of 8 to 50 weight percent, preferably 9 to 40 weight percent based on the total weight of the poly(ethylene vinylacetate) copolymer present in the foamable composition.

Specifically, the resin can be an ethylene vinyl acetate (EVA) copolymer. Commercially available poly(ethylene vinylacetate) copolymers include, e.g., AT Polymers 1070C (9 wt % vinyl acetate (VA)), AT Polymers 1710 (17 wt % VA), AT Polymers 2306 (23 wt % VA), AT Polymers 2803 (28% VA), AT Polymers 2810 (28 wt % VA), Chevron/Ace Plastics TD 3401 (9.5 wt % VA), Chevron/Ace Plastics DS 4089-70 (18% VA), DuPont Elvax® 40 W (40 wt % VA), DuPont Elvax® 140-W (33 wt % VA), DuPont Elvax® 250-W (28 wt % VA), DuPont Elvax® 260 (28 wt % VA), DuPont Elvax® 350 (25 wt % VA), DuPont Elvax® 360 (25 wt % VA), DuPont Elvax® 450 (18 wt % VA), DuPont Elvax® 460 (18 wt % VA), DuPont Elvax® 550 (15 wt % VA), DuPont Elvax® 560 (15 wt % VA), DuPont Elvax® 650 (12 wt % VA), DuPont Elvax® 660 (12 wt % VA), DuPont Elvax® 750 (9 wt % VA), DuPont Elvax® 760 (9.3 wt % VA), DuPont Elvax® 770 (9.5 wt % VA), Exxon Escorene® LD-740 (24.5 wt % VA), Exxon Escorene® LD-724 (18 wt % VA), Exxon Escorene® LD-721.62 (19.3 wt % VA), Exxon Escorene® LD-721.88 (19.3 wt % VA), Exxon Escorene® LD-721 (19.3 wt % VA), Exxon Escorene® LD-740 (24.5 wt % VA), Exxon Escorene® LD-318 (9 wt % VA), Exxon Escorene® LD-319.92 (9 wt % VA), Exxon Escorene® LD-725, Quantum UE 630-000 (17 wt % VA), Quantum 637-000 (9 wt % VA), Rexene® X1903 (10 wt % VA), Rexene® X0901 (12 wt % VA), Rexene® X0911 (18 wt % VA), Taisox® 7360M (21 wt % VA), Elvax® 2288 from DuPont. Chemical Co., (21 wt % VA) and Rexene® X0915 (9 wt % VA).

The poly(ethylene vinylacetate) copolymer may optionally be present in the foamable composition in an amount of 20 to 40 wt %, preferably 25 to 35 wt % and more preferably 27 to 33 wt %, based on the total weight of the foamable composition.

The foam may be produced by a number of processes, such as compression molding, injection molding, or combinations of extrusion and molding. The foamable composition may be manufactured by blending together the elastomer, the carboxylated olefin copolymer, the crosslinking agent, the blowing agent, and any other desired additives. The blending may be conducted in an extruder or internal mixer, or alternatively, the ingredients may be pre-blended in a dry blender prior to being extruded in the extruder or mixed in the internal mixer.

In one embodiment, manufacturing the foam can comprise mixing the elastomers, the carboxylated olefin copolymers, the blowing agent and the crosslinking agents under heat to form a melt. This may be conducted in a Banbury , intensive mixers, two-roll mill, or in an extruder. Time, temperature, shear rate may be regulated to ensure optimum dispersion without premature crosslinking or foaming. A high temperature of mixing may result in premature crosslinking and foaming by decomposition of peroxides and blowing agents. An adequate temperature may be desired to insure good mixing of and dispersion of other ingredients. The upper temperature limit for safe operation may depend on the onset decomposition temperatures of peroxides and blowing agents employed. The ingredients can form a uniform mixture when blended at temperatures of 60° C. to 150° C., preferably 70° C. to 140° C., and more preferably 80° C. to 130° C., and even more preferably 90° C. to 120° C. The polymers may be melt-blended before compounded with other ingredient(s).

After mixing, shaping can be carried out. Sheeting rolls or calendar rolls are often used to make appropriately dimensioned sheets for foaming. An extruder may be used to shape the composition into pellets.

Foaming can be carried out in a compression or injection mold at a temperature and time to complete the decomposition of peroxides and blowing agents. Pressures, molding temperature, and heating time may be controlled. Foaming can be carried out in an injection molding equipment by using foamable composition in pellet form. The resulting foam can be further shaped to the dimension of finished products by any means known in the art such as by thermoforming and compression molding.

The foam produced from the composition can be substantially closed cell and useful for a variety of articles including footwear application (e.g., midsoles or insoles), automotive seal and interiors, furniture armrest, railway pad, and other industrial foam material applications.

The foamable composition and the method of manufacture thereof are disclosed by the following non-limiting examples.

EXAMPLE

This example was conducted to demonstrate the preparation of the disclosed foamable composition and its properties. The materials used in the examples and in the comparative examples are detailed in the Table 1 below.

TABLE 1 Ingredient Description OBC Dow product, olefin block copolymer density 0.877 g/cc, 1 MI @ 2.16 kg/190° C. EVA DuPont product, ethylene vinyl acetate copolymer, 21% VA level, 2.2 MI @ 2.16 kg/190° C., density 0.95 g/cc. E-MAA DuPont product, ethylene methyl acrylic acid copolymer, 3 MI@ 2.16 kg/190° C., density 0.93 g/cc LUPEROX ® F40P Dicumyl peroxide from Arkema with active peroxide content around 40 wt %. AC 6000HG Azodicabonamide type blowing agent from Hai Hong (China) company ZnO Zinc oxide, local grade ZnSt Zinc stearate, local grade Talc SK-6500P, Industrial grade TiO₂ R-103 from Chemours

The ingredients were compounded together via internal mixer. Then the formulated compounds were fabricated in the two-roll mill and followed by bun foaming. The prepared foam plaque was sliced into suitable dimensions for further testing. The compounding and bun foaming manufacturing operations are detailed below.

The compounding of the foamable composition is as follows. Polymer pellets (having the compositions shown in the Tables 2 and 3 below) were added to a 1.5 liter, Banbury mixer. Fillers comprising zinc oxide (ZnO), zinc stearate (ZnSt) and talc are added to the Banbury after the polymer melted (around 5 minutes). The blowing agent and peroxide were added last, after the fillers were uniformly dispersed, and the contents mixed for another 3 to 5 minutes for a total mixing time of 15 minutes. The batch temperature was checked by using a thermal probe detector right after the compounds were discharged. The compositions actual temperature was generally 10 to 15° C. higher than the displayed temperature on the equipment (actual composition temperature was around 120° C.). Hence, during the compounding process, it is better to maintain a lower displayed equipment temperature to ensure the compound temperature docs not exceed the decomposition temperature of the curing agent and the decomposition temperature of blowing agent. The compounded formulation was then placed between two roll mills (maintained at a temperature of about 120° C.), and the compounded formulation was formed into a sheet (or roll milled blanket) of about 5 mm in thickness.

The bun foam manufacturing is detailed below. Roll milled blankets were cut into squares (three or four “6 inch×6 inch” squares), and placed inside a pre-heated bun foam mold of dimensions around 49 square inches. The surface of the chase was sprayed with mold releasing agent, to avoid sticking of the foam to the chase during de-molding. Two compression molding processes were involved: first a preheating process to eliminate air pockets inside the sample and between the stacked blanket layers prior to curing, and then a second healing step to facilitate the curing/foaming process. The preheating was conducted for 8 minutes at 110° C. (low inching polymer like ENGAGE™ POE or Elvax® EVA) or 120° C. (high melting polymer like INFUSE™ OBC), and pressed at 10 tons, for 4 minutes, to form a solid mass in the mold before foaming. The preheated mass was transferred to the foaming press, and held for 8 minutes at 100 kg/cm² and 180° C. Once the pressure was released, the bun foam was removed quickly from the tray, and placed in a vent hood on several non-stick sheets, and the top side length was measured as soon as possible. The foam surfaces needed to be insulated from the bench top, using cardboard boxes. Insulating the surfaces of the newly made bun foam prevents uneven cooling on the top and bottom surface. The foams cool in the hood for 40 minutes following which they were transferred to a storage container, and allowed to cool for 24 hours.

The following tests were performed on the foamed composition.

-   -   Foam Density: Bun foams were weighed to the nearest 0.1 g, and         volume determined by measuring length, width, and thickness to         the nearest 0.01 cm. The density could be calculated in terms of         weight and volume.     -   Compression Set: Compression Set (C-Set) was measured per ASTM         D395 method B under conditions of 50% compression at 50° C. for         6 hours. Two buttons were tested per foam and the average         reported. The compression set was calculated by using the         following equation:

Compression set=(T ₁-T ₂)/(T ₁-T ₀)*100%

where T₀ is the interval distance of the apparatus, T₁ is the sample thickness before test and T₂ is the sample thickness after test.

-   -   Asker C Hardness: The Asker C hardness test was conducted         according to ASTM D2240. The hardness was an average of five         readings (5 seconds latency) measured across the surface of the         sample and measured again after aging 40 minutes at both 70 and         100° C.     -   Split Tear Resistance: The split tear strength was measured by         using a specimen with the dimension of 6″ (length) * 1″         (width) * 0.4″ (thickness) and the notch depth of 1˜1.5″ at the         testing speed of 2 inches/minute according to ASTM D3574.     -   Compressive Strength: Compressive Strength was performed         according to ASTM D1621. A 29 mm diameter circle foam samples         was pressed at uniform rate of 1 mm/min. The stress required to         produce compression strain up to 25% was determined. Where         compressive strength was given by the force per unit area based         on the original foam cross-section.

Table 2 lists the compositions for the inventive examples (IE) and the comparative examples (CE). All numbers for the respective compositions are in parts per hundred. The comparative examples (CE-1 through CE-4) do not contain any carboxylated olefin copolymer. The inventive examples (IE-1 through IE-6) all contain carboxylated olefin copolymer in amounts of 5 wt % or 10 wt % based on the total weight of the resin in the foamable composition.

Table 2 lists the inventive examples based on the current invention as well as the corresponding comparative examples. CE-1 to CE-4 are the comparative examples based on OBC without any acid containing polymers. IE-1 to IE-3 and IE-4 to IE-6 are the inventive examples having compositions similar with CE-1 except that they contain 5 (IE-1 to IE-3) and 10 phr (IE-4 to IE-6) of the acid containing polymer. The experimental results for the inventive samples (IE-1 to IE-3 and IE-4 to IE-6) and those of the comparative sample (CE-1 to CE-4) are listed in the Table 3 below.

Table 3 lists other comparative foamable compositions (CE-5 to CE-7) where polyethylene vinylacetate is used as the elastomer in lieu of INFUSE™ olefin block copolymers.

TABLE 2 (Formulations of Inventive and Comparative Foam Examples) OBC OBC + 5% E-MAA OBC + 10% E-MAA Ingredient CE-1 CE-2 CE-3 CE-4 IE-1 IE-2 IE-3 IE-4 IE-5 IE-6 OBC 100 100 100 100 95 95 95 90 90 90 E-MAA 5 5 5 10 10 10 R103 (TiO₂) 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 SK6500P(Talc) 5 5 5 5 5 5 5 5 5 5 ZnSt 1 1 1 1 1 1 1 1 1 1 ZnO 2 2 2 2 2 2 2 2 2 2 AC 6000HG 2.8 3.0 3.2 3.4 3.2 3.6 3.0 3.2 3.4 3.0 F40P (BIPB) 1.50 1.50 1.50 1.50 1.50 1.50 1.38 1.50 1.50 1.38 Density, g/cc 0.188 0.175 0.178 0.159 0.181 0.162 0.160 0.187 0.177 0.155

TABLE 3 (Formulation for EVA and EVA/E-MAA blend based foam) Ingredient CE-5 CE-6 CE-7 EVA 100 95 90 E-MAA 5 10 R103 (TiO₂) 2.5 2.5 2.5 RB510 (Talc) 5 5 5 ZnSt 1 1 1 ZnO 1.5 1.5 1.5 AC 6000HG 2.6 2.2 1.8 F40P (BIPB) 1.375 1.375 1.375 Density, g/cc 0.199 0.197 0.201

FIG. 2 depicts the curing curves measured by a moving die rheometer (MDR) for the olefin block copolymer (OBC) system with or without the ethylene-methacrylic acid (E-MAA) copolymers at the same peroxide level. FIG. 2 is a graph that depicts MDR curing torque of OBC system with (IE-1 and IE-4) or without (CE-3) E-MAA copolymer. The addition of E-MAA significantly improves the curing level. In contrast, in the EVA system (see FIG. 3), the curing behavior is quite different from what is observed in the OBC system. FIG. 3 is a graph that depicts MDR curing torque of EVA system with or without (CE-5˜CE-7) E-MAA copolymer. The EVA/E-MAA system displays lower curing level at the beginning and then surpasses the EVA curing curve after 5 minutes.

FIG. 4 is a graph of foam hardness for an OBC foam with or without E-MAA at different foam densities. Adding 5 or 10 phr of E-MAA significantly improves the foam hardness (FIG. 4) at the same density, which is particularly useful for a lightweight foam where the hardness still should not be compromised (i.e., not be reduced).

FIG. 5 compares the compression force of OBC foam at different foam densities with or without E-MAA copolymer. FIG. 5 is a graph of foam compressive strength of an OBC foam with or without E-MAA. The OBC/E-MAA based foam displays a higher compression force across the whole density range (0.15 g/cc˜0.2 g/cc). The increased compressive strength indicates a better supporting ability of the foamed midsole towards human body. The lower the foam density, the more difficult it is for the foam to display any supporting ability. The increase in compression force means that at the same foam deformation ratio the midsole can support a higher weight or the foam could deform less under the same compression force.

A property that reflects foam durability is compression set recovery. FIG. 6 is a graph of compression set against split tear for OBC foam at different foam densities with or without E-MAA. Typically the compression set resistance will be improved (better durability) but the split tear will be hurt with increased curing level, and it is difficult to get a balance in lightweight foam. In the current invention, the plot of compression set against split tear indicates that the addition of E-MAA could generate lower compression set at the given split tear strength.

FIG. 7 is a graph of compression set against foam density for OBC and EVA foam with or without E-MAA. FIG. 7 summarizes the compression set of OBC or EVA system with or without E-MAA at different foam densities. In the OBC system, the addition of E-MAA dramatically improves the compression set resistance (i.e., it displays a lower compression set percentage) compared with a pure OBC foam (without the E-MAA). However, in the EVA system, the compression set number was high and was even increased due to a decrease of curing level.

FIG. 8 is a spider graph that compares the foam performance of CE-2 and IE-6. It is clear the IE-6 offers a higher split tear resistance at a much lower density while still maintaining the other performance characteristics.

These experiments show that with an increased amount of the ethylene methacrylic acid in the foamable composition and a higher ratio of the activator to the carboxylic acid copolymer, the foam expansion ratios were still similar and the corresponding foam density could be still lower or equal to 0.23 g/cc, preferably lower or equal to 0.22 g/cc or more preferably low er or equal to 0.20 g/cc.

From the figures, it may be seen that the disclosed foams have an Asker C hardness of 40 to 60. In an embodiment, the disclosed foams have an Asker C hardness greater than 42, preferably greater than 43. and more preferably greater than 44 when measured as per ASTM D2240.

The foams also display a compression set oflcss than 50%, when measured as per ASTM D395 method B. The foams display a split tear of over 2.4 N/mm when measured as per ASTM D3574.

The density of the foam is greater than or equal to about 0.15 g/cc, preferably greater than or equal to about 0.16 g/cc, preferably greater than or equal to about 0.17 g/cc, preferably greater than or equal to about 0.18 g/cc. The foam may have a density of less than or equal to 0.23 g/cc, and less than or equal to 0.22 g/cc. These properties make the foani suitable for use in footwear as a shoe sole. 

1. A foamable composition comprising: an olefin copolymer that comprises ethylene and an α-olefin; an unneutralized carboxylated olefin copolymer; a crosslinking agent; a blowing agent; and an activator that comprises a metal oxide, a metal hydroxide, a metal salt, or a combination thereof, wherein: a weight ratio of the activator to the unneutralized carboxylated olefin copolymer is greater than 0.3; the carboxylated olefin copolymer is present in the foamable composition in an amount of 5 wt % to 20 wt %, based on a total weight of the resin in the foamable composition; and the carboxylated olefin copolymer comprises a carboxylic acid.
 2. The foamable composition of claim 1, wherein the olefin copolymer is an olefin block copolymer and is present in the foamable composition in an amount of 60 wt % to 90 wt %, based on the total weight of the foamable composition.
 3. The foamable composition of claim 1, wherein the α-olefin is 1-octene.
 4. The foamable composition of claim 1, wherein the carboxylated olefin copolymer is present in the foamable composition in an amount 5 wt % to 10 wt %, based on a total weight of the resin in the foamable composition.
 5. The foamable composition of claim 1, wherein the carboxylic acid is acrylic acid or methacrylic acid.
 6. The foamable composition of claim 1, wherein the crosslinking agent is a peroxide, and wherein the blowing agent is an azodicarbonamide.
 7. The foamable composition of claim 1, wherein a foam manufactured from the foamable composition has a density of 0.15 g/cc to 0.20 g/cc, an Asker C hardness of 40 to 60 when measured as per ASTM D2240, and a split tear of greater than 2.4 N/mm when measured as per ASTM D3574.
 8. An article manufactured from the foamable compositions of claim
 1. 9. The article of claim 8, wherein the article is footwear shoe sole.
 10. A method of manufacturing a foamable composition, the method comprising: blending together an olefin copolymer that comprises ethylene and α-olefin, an unneutralized carboxylated olefin copolymer, a crosslinking agent, a blowing agent, and an activator to form the foamable composition, wherein a weight ratio of the activator to the unneutralized carboxylated olefin copolymer is greater than 0.3; and heating the foamable composition to activate the blowing agent and crosslinked agent to form a crosslinked foam.
 11. The method of claim 10, further comprising molding the foamable composition. 